Stone, metal and tar laminate for exterior cladding

ABSTRACT

An exterior cladding that combines the benefits of stone, metal and tar in a laminate form that makes the most with the least expensive forms of each of these three base materials. A construction laminate having an asphaltic core body covered with a metallic facing on a top side and part of a bottom side. A granular coating is applied to the metallic facing on the top side and front edge. The laminate is useful as exterior cladding such as a roofing shingle, siding etc. . . . and is durable and easy to install.

FIELD OF INVENTION

This invention relates to a laminate for use as an exterior claddingconstruction material, for example, wall panels and roof tiles. Inparticular, the invention relates to a laminate which combines threehistorically proven raw materials: stone, metal and tar.

BACKGROUND OF THE INVENTION

Since the beginning of time, human beings have sought improved materialsfor shelter. Most of what was used thousands of years ago is still inuse today, in one form or another. For example the stone used in cavesis used as slate roofing or granite walls. Mud is transformed intobricks and leaves are used in thatch roofing. Modern cladding originatesfrom one form of or a combination of very basic materials.

The historic benefits of stone, metal and tar don't come without somedrawbacks. For example stone, including slate and granite, is verydurable and resistant to the sun's ultraviolet UV rays but it is alsovery heavy and rigid. Metal such as copper and aluminum is relativelylightweight and can be bent into any shape but installation can be veryspecialized and the resulting structure is susceptible to condensationleaks. Tar including bitumen and asphalt is also lightweight and verywaterproof but does not last very long in the sun and has very littlebody so that it is flimsy to handle. Improvements have been made bymodifying or combining the materials with each other.

Asphalt shingles, by far the most popular roof cladding in NorthAmerica, is basically tar and gravel supported by saturated felt. Thestone granules in the gravel delay deterioration of the tar from UV raysand the tar holds the granules in place. Although this is a greatinnovation, the effect of the UV rays on the tar is not eliminated andthe asphalt shingles eventually do shed their granules, curl, crack andlift from the underlying wood panels, and although they are laid in anoverlapping manner, the shingles need to be replaced. Depending on thethickness of the shingle, and the trend has been towards thinnershingles, it is generally recommended to replace the roof shingles everyten to fifteen years.

Metal tiles are becoming more popular. However, they still suffer fromthe drawback that they are expensive because of the cost of the tileitself and also the complexity of installation and warehousing. Suitablemetals for use in roof tiles are galvanized steel, aluminum, zinc orcopper. Another disadvantage is that snow and ice easily slide off ametal roof and this creates a potential hazard to persons walking orworking adjacent to the building or home and can destroy property suchas eavestroughs, lower roofs, decks, vehicles and the like. Foroccupants of the home, the noise from rain falling on the roof can alsobe disturbing and condensation problems have also been observed. Anotherdisadvantage is that smooth metal has a commercial look and the colorwill fade when exposed to UV rays.

One solution to these problems has been the application of a simulatedstone covering to the metal tile. This reduces noise transmission to theinterior of the building structure, restrains movement of snow and ice,remains colorfast and more residential in appearance. This process hasimproved since its start in 1956 and is now accepted as a proven processworldwide. A series of recent patents issued to BASF Corporation,including U.S. Pat. No. 6,540,829 provide a system for coating sheetmetal coil with a resinous composition and embedding granular materialin the wet surface of that coating to simulate the appearance of atraditional mineral covered asphalt shingle.

US 2002/0116886 provides a simulated wood shake made of metal which hasa stone-chip coating to form a pattern of differently colored areas, theareas being coordinated with alternating raised and lowered sections ofthe metal roof panel. The product is a successful simulation of woodshakes but it is still expensive and difficult to install primarilybecause the metal needs to be sufficiently thick to maintain its shapeunder pressure and specialized installation accessories are required.

Another stone coating innovation is an exterior cladding consisting of amixture of stone granules in an acrylic resin which is applied on anexterior wall system using a trowel. This demonstrates the use ofsynthetic adhesives to replace tar, and results in a cladding which ismore resistant to UV rays.

A foil faced bitumen products is currently available and sold inassociation with the trademark Tegola®. This allows the cladding to bemade thinner and easier to apply to a roof deck surface while giving ita protective layer of metal so that it can last longer. An exemplarydescription of a metal clad asphalt shingle is provided in U.S. Pat. No.3,607,529 issued to Alcan Aluminum Corporation in 1971. One problem withthis shingle is that the metal covers the whole of the backside,eliminating the sealing qualities of the tar. Another problem is thatthe weak unprotected metal foil is easily susceptible to scratches,puncture, tearing, fading and delamination.

Applicant is aware of only one attempt at combining stone, metal and tarto produce a superior cladding laminate. This was a New Zealand rooftile consisting of stone granules imbedded into a bitumen-based adhesiveoriginating from a WWII British innovation branded as Decramastic andapplied to a metal panel. These were supposed to last a lifetime.Instead, the granules would shed after only a few years. As a solution,the bitumen was eliminated and replaced with acrylic. The concept was toprotect the metal, which was primitive galvanized steel sheets which hada tendency to rust easily from scratches and simple elements with abituminous coating. The stone chips were only introduced by chance, andnot for their UV resistant qualities, when sand was applied to thebitumen to solve the problem of panels sticking together in theshipping. When the aesthetic qualities of the sand were noticed, theybegan to use color co-coordinated natural stone chips. Althoughstone-coated metal is a great innovation, it still relies on thethickness of the metal for structural strength, walkability and watertightness.

An object of this invention is to provide an improved exterior claddinglaminate which combines the beauty and protection of stone with thedurable and preserving qualities of metal and the water repellingqualities and easy installation of tar including asphalt and bitumen.Significant material cost savings also may be achieved by selectingthinner and lighter materials which also makes the product easier tohandle, cut and install hence also reducing installation costs.

SUMMARY OF THE INVENTION

In accordance with this invention, there is provided a constructionlaminate for use as an exterior cladding, the laminate having aplurality of layers including an asphaltic core body, a metallic facingapplied to cover or partially cover an operatively outer side of theasphaltic core body to protect the asphaltic core body in exposed areas,and a granular coating applied to the metallic facing to provide anexterior stone coating appearance to the exterior cladding.

Most preferably, the asphaltic core body has an inner side which iscoated to prevent sticking of laminates which are stacked fortransportation to a work site and an adhesive tab, which can be coveredwith a release tape, for securing the laminates at the location wherethey are used.

The granular coating may be applied using a resinous coating applied tothe metallic facing and protected with a seal applied over or mixed withthe granular coating.

BRIEF DESCRIPTION OF THE DRAWINGS

In order to better understand the invention, a preferred embodiment isdescribed below with reference to the accompanying drawings, in which:

FIG. 1 is a cross-sectional view of a construction laminate made inaccordance with the invention;

FIG. 2 is a perspective view of the construction laminate of FIG. 1;

FIGS. 3 a to 3 c are cross-sectional views of a roofing tile made inaccordance with the invention each having different thicknesses;

FIG. 4 a is a top plan view of a plurality of roofing tiles made inaccordance with the invention and disposed to lie over each other inoverlapping fashion;

FIG. 4 b (drawn adjacent FIG. 4 a) is a cross-sectional view of a pairof overlapping roofing tiles of FIG. 4 a;

FIG. 5 is a cross-sectional view of a plurality of roofing tilesdisposed to lie over each other in overlapping fashion;

FIG. 6 is a top plan view of a roofing tile made in accordance with theinvention;

FIG. 7 a is a top plan view of a wall panel made in accordance with theinvention;

FIG. 7 b (drawn adjacent FIG. 7 a) is a cross-sectional view of aplurality of wall panels disposed to lie over each other in overlappingfashion and an associated wall surface;

FIG. 8 a is a plan view of an alternative embodiment of a constructionlaminate made in accordance with the invention;

FIG. 8 b is a plan view of a plurality of construction laminates of thekind shown in 8 a disposed side by side;

FIG. 8 c is a cross-sectional view of a plurality of the laminates shownin FIG. 8 b mounted side by side on a supporting surface.

DESCRIPTION OF PREFERRED EMBODIMENT WITH REFERENCE TO DRAWINGS

A preferred embodiment of the invention is described with reference tothe accompanying drawings in which a construction laminate is generallydesignated by reference numeral 20. The construction laminate 20 shownin FIGS. 1 and 2 has an asphaltic core body 22 consisting of bituminousmaterials commonly used for roofing applications also known as asphaltor tar and typically having a thickness of 0.3 to 25 mm or more, iffillers are added. Suitable materials will include asphalt saturated orasphalt coated web type materials which will include the following:felt, fiberglass, polyester, paper, polypropylene, and polyethylene.This list is not meant to be exhaustive but only exemplary of the typeof material contemplated for use as the asphaltic core body comprisingthe invention. Fillers may consist of beads or sheets of polystyrene orother synthetic plastic materials embedded in asphalt for added bulk toincrease thickness in the laminate.

The asphaltic core body 22 supports all the other elements comprisingthe construction laminate and is a material with which constructionexperts are familiar and for which installation is not problematic. Theasphaltic core body 22 is wrapped with a metallic facing 24 that coversan operatively outer side of the asphaltic core body 22, a forward edge(drawn to the right of FIG. 1) and a portion of an inner side adapted tocover and protect an underlying surface (not shown) from the elements.The metallic facing 24 is made of metal sheet which is thin enough andmalleable enough to allow it to conform to the shape of the asphalticcore body 22. Any suitable metal may be applied and selected accordingto the intended application and its availability and cost. Inparticular, it is contemplated that the metallic facing will be sheetmetal selected from the group comprising steel, aluminum, copper, zinc,tin, alloys of aluminum and zinc commonly sold under the trademarkGALVALUME and galvanized steel. Most preferably, the metallic facing 24is adhesively attached to the asphaltic core body 22 by an adhesiveasphalt coating which when warmed sufficiently can be tacky in nature.The metallic facing 24 will have a thickness between 0.015 mm and 1.000mm and it may be given any desired color, for example, by coating themetallic facing with a suitable resin. It will be understood that thethickness of the metallic facing 24 is reduced as much as possible tominimize costs while being thick enough to resist impacts from debrissuch as branches or from hail stones. Where cost is not a concern, themetal facing 24 can be made as thick as known metal cladding. Themetallic facing 24 also operates to preserve and reinforce theunderlying asphaltic core body 22.

A protective granular coating 26 is applied over the metallic facing 24so as to cover at least a portion of an outer surface. The combinationof the granular coating 26 with the asphaltic core body 22 gives themetallic facing 24 sufficient support and strength to allow one to use ametal facing with minimum thickness and still have a durable andwalkable surface. The granular coating 26 is primarily selected to givethe construction laminate a more aesthetic appeal and will be selectedaccordingly from materials which may include the following: stone, stonechips, sand, ceramics, quartz, mica, slag, plastic, glass andcombinations of the foregoing. The irregular texture provided by agranular coating 26 will also operate to increase resistance to slidingso that it is safer to walk on a roof cladding which has been made fromthe construction laminate 20 and to prevent sheets of ice and snow fromsliding off a roof and thereby endangering passersby. The granularcoating 24 also absorbs UV rays to further protect the other components.

In a preferred embodiment of the invention, the granular coating 26 isapplied to the exterior surface of the metal facing 24 by first coatingthe metallic facing with a resinous coating such as acrylic or epoxywhich is tacky and will retain the granular coating on its surfacebefore it is dry. The resinous coating layer is generally indicated byreference numeral 28 in FIG. 1 and its thickness is exaggerated forillustration purposes. It will be understood that the resinous coating28 will embed the components forming the granular coating 26 and willnot be apparent as a distinct layer. Suitable substitutes for theresinous coating 28 will be apparent to those skilled in the art. Itwill also be understood that the resinous coating 28 may be tinted inorder to provide the aesthetic finish desired and will of course vary inthickness according to the adhesion forces required to secure thegranular coating. The resinous coating can also be mixed with thegranules and applied simultaneously.

The assembly is completed by providing a protective sealant layer 30over the granular coating 26. The sealant 30 which likewise has itsthickness exaggerated in FIG. 1 for illustration purposes may consist ofacrylic, epoxy, silicone and other materials as will be apparent tothose skilled in the art and it may be clear or color tinted.

While exterior cladding is intended to be mounted to an underlyingsurface (not shown) such as a roof deck using conventional fasteners,including mechanical fasteners such as nails, it is suggested thatconstruction laminates 20 made in accordance with the invention besecured to each other in an overlapping fashion using an adhesive tab32. Preferably, the adhesive tab 32 is a bitumen-based material which islocated on the inner side of the asphaltic core body 22 so as to overlapthe asphaltic core body and the metallic facing 24 of an underlyinglaminate 20. The tab 32 may be formed as a continuous tape or consist ofa plurality of spaced tab elements. The location of the tab 32 at thejoint between the metal facing and the asphaltic core body reinforcesthe seal at a key weak area. Preferably, the outer surface of the tabs32 is covered with a release tape (not shown) commonly used in theindustry, to prevent sticking while shipping.

During transportation to a jobsite, it is desirable for the constructionlaminates to be stacked and for the individual laminates 20 to remainseparate. Therefore, the preferred embodiment of the invention providesfor an additional parting layer or undercoat 34 applied to the innerside of the asphaltic core body 22. A suitable material to use for theparting layer 34 is a fine granular material disposed in an adhesivecoating which will be selected to be as economical as possible.

In use, it will be appreciated that the invention provides enormousadvantages over the construction materials of the prior art,particularly those that have been used as roofing materials. Thus theproblems associated with asphalt tiles that crack, curl and shed areovercome by reinforcing and preserving the asphaltic core body 22 withthe metallic facing 24 and granular coating 26. Conversely, theasphaltic core body operates to weatherproof the metallic facing 24 toimprove corrosion resistance and minimize infiltration of condensationonto a supporting surface. Since the thinnest possible metal sheet canbe used, the expense of metal cladding does not need to be incurred.

Particular forms of exterior cladding embodying the invention will nowbe described with reference to FIGS. 3 a to 8 c.

A number of roofing tiles made in accordance with the invention and eachhaving a different thickness, are shown in FIGS. 3 a to 3 c. In FIG. 3a, a roofing tile is generally designated by reference numeral 40 andincludes an asphaltic core body 42, a metallic facing 44 applied tocover a portion of the operatively outer side of asphaltic core body(topside as drawn in FIG. 3 a) and adapted to leave the asphaltic corebody 42 bare in areas which will be covered by adjacent roofing tiles asshown in the cross-sectional views of FIG. 4 b and FIG. 5. The metallicfacing 44 also covers the forward edge (drawn to the right of FIG. 3 a)of the asphaltic core body 42 and a portion of the inner side (drawn onthe bottom of FIG. 3 a) of the asphaltic core body adjacent to theforward edge. The metallic facing 44 is thereby adapted to protect theunderlying asphaltic core body 42 in exposed areas thereof as shown inthe plan view of FIG. 4 a.

The exposed areas are further protected by a granular coating 46 appliedto the metallic facing 44 to cover substantially an outer surface of themetallic facing 44 and a forward edge (drawn to the right of FIG. 3 a).The granular coating 46 leaves the metallic facing 44 bare in an areaadjacent to the bare area of the asphaltic core body which as can beseen most clearly in FIG. 4 b is adapted to receive a mechanicalfastener or nail which couples the bare metallic facing 44 to the bareasphaltic core body 42 and an underlying surface (not shown). It will benoted that the metallic facing 44 is also bare on a portion covering theinner side of the asphaltic core body (drawn on the bottom of FIG. 3 a).In this way, the granular coating 46 is adapted to provide an exteriorstone coating appearance to the roof tile 40 as is more apparent fromFIGS. 4 a, 4 b and 5 where all exposed areas are visible.

The roofing tile 40 also has an adhesive tab 50 on the inner side (drawnat the bottom of FIG. 3 a) and disposed to lie partially over themetallic facing 44 and the asphaltic core body 42. As described withreference to the construction laminate of FIG. 1, the tab may beprovided with a release tape and be formed in longitudinally extendingstrips or consist of a plurality of tab sections disposed side by sidealong the length of the joint between the metallic facing and theasphaltic core body. As can be seen most clearly with reference to thecross-sectional views of FIGS. 4 b and 5, the adhesive tab 50 ispositioned in order to bond metal to metal between adjacent roofingtiles and asphalt to asphalt in adjacent roofing tiles which aredisposed to lie over each in overlapping fashion. Thus, when the roofingtile 20 is exposed to the sun, the bottom surface is heated to cause theadhesive tab 50 to become tacky so that it will adhere to adjoiningsurfaces. As demonstrated by the cross-sectional view of FIG. 5, eachroofing tile 40 is secured at three points consisting of the fastener48, the adhesive tab 50 of the roofing tile and the adhesive tab 50 ofan overlying roofing tile. Installation of the roofing tiles is thusvery easy to perform and does not require any specialized tools oraccessories. The resulting seal between adjacent tiles is weather proofthereby improving the durability of the resulting roof structure.

In FIG. 3 a as in the remaining figures, the roofing tile has been drawnto omit layers corresponding to the release coating 34 of FIG. 1, theresinous coating 28, and the sealant layer 30, for simplicity. It willof course be understood that these materials may form part of theroofing tile and they will be applied in the manner described withreference to FIGS. 1 and 2. Further the materials comprising theasphaltic core body, the metallic facing 44, and the granular coating 46will correspond to the materials described with reference to FIG. 1 andlayers 22, 24, and 26 respectively.

In FIG. 3 b a roofing tile 52 is shown in which the asphaltic core body54 is drawn to have a greater thickness thereby exemplifying anembodiment in which the body may include fillers such as polystyrenebeads embedded in the asphalt, as described above with reference toFIG. 1. As the remaining layers correspond to those shown in FIG. 3 athey have been assigned like reference numerals in the drawing.Likewise, in FIG. 3 c a still thicker roofing tile 56 is shown having astill greater thickness imparted by the asphaltic core body 58 and asomewhat thicker metallic facing 60. Varying the thickness of theasphaltic core body as demonstrated by FIGS. 3 b and 3 c and themetallic facing as demonstrated in FIG. 3 c allows one to fabricate theroofing tile with a three dimensional profile which is not planar andwhich can give the laminate additional architectural appeal if this isdesired.

With planar tiles, architectural appeal may also be provided by varyingthe color and distribution of the granular coating 46. As will be seenin FIG. 4 a, the granular coating 46 is disposed to leave selected areasof the underlying metallic facing 44 bare so as to simulate theappearance of a three tab shingle. Alternatively, as shown in FIG. 6 a,the granular coating 46 may be uniformly distributed across the entirelength of the roofing tile 40.

In an alternative embodiment of the invention shown in FIG. 7 a and 7 b,the construction laminate is shown for use as exterior cladding on anunderlying wall surface indicated by reference numeral 62. The wall tile64 shown in FIGS. 7 a and 7 b has a similar profile to the roofing tile40 shown in FIGS. 4 to 6 and consists of an asphaltic core body 66having an inner side adjacent to the wall surface 62 so as to cover andprotect the wall. The outer side has a metallic facing 68 which protectsthe underlying asphaltic core body 66 in exposed areas and a granularcoating 70 is applied to the metallic facing 68 to provide an exteriorstone coating appearance to the wall cladding. The wall tiles 64 areapplied to the wall surface 62 using nails 72 and adhesive tabs 74 inthe manner described above with reference to the roofing tiles 40.

A still further embodiment of a construction laminate made in accordancewith the invention and which may for example be used as wall cladding orfloor cladding, is shown in FIGS. 8 a to 8 c. It will be assumed thatappropriate durable materials will be selected to fabricate a floortile. In the drawings, a wall tile is designated by reference numeral80. The wall tile has sides of equal length so that it has a squareappearance as shown in the plan view of FIG. 8 a. As in the otherembodiments described, the wall tile 80 has an asphaltic core body 82but in this case, the metallic facing 84 is co-extensive with theasphaltic core body so as to cover the entire exposed surface of thewall tile 80, the side edges, as well as a portion of the inner side ofthe asphaltic core body 82 adjacent to an underlying wall surface 86. Agranular coating 88 is applied to the metallic facing 84 so as to beco-extensive with an outer surface and side edges so as to provide anexterior stone coating appearance to the wall cladding. As in the otherembodiments described, each tile is provided with adhesive tabs 90 whichoverlap the joint between the metallic facing 84 and the asphaltic corebody 82 on an inner side thereof so as to couple the tiles 80 to thelower surface 86. The assembly is further secured by nail fasteners 92which penetrate the entire thickness of the tiles 80 so as to couple thetiles to the underlying wall surface 86.

It will be understood that several variations may be made to theabove-described embodiment of the invention within the scope of theappended claims. In particular, it will be understood that theconstruction laminate may find many applications which are not limitedto the cladding of a roof deck. The laminate could for example be usedas a decorative or functional cladding for interior walls or exteriorwalls and, provided the granular coating 26 is sufficiently durable, itmay also be applied as a flooring material.

1. A construction laminate for use as exterior cladding on an underlyingsurface, the laminate having a plurality of layers including at leastthe following: an asphaltic core body having an operatively outer sideand an inner side adapted to cover and protect the underlying surfacefrom elements; a metallic facing applied to cover at least a portion ofsaid operatively outer side of the asphaltic core body, to protect theunderlying asphaltic core body in exposed areas thereof, the metallicfacing covering only a portion of the outer side of the asphaltic corebody leaving the outer side of the asphaltic core body bare in areaswhich are adapted in use, to be covered by adjacent laminates disposedto lie over each other in overlapping fashion, the metallic facingincluding an area adapted to receive a mechanical fastener andpositioned adjacent the bare area of the outer side of the asphalticcore body, the metallic facing also covering a forward edge of theasphaltic core body and a portion of the inner side of the asphalticcore body adjacent said forward edge; and a granular coating applied tosaid metallic facing to cover at least a portion of an outer surfacethereof, the combination of the granular coating with the asphaltic corebody supporting and strengthening the metallic facing, the granularcoating also covering said forward edge for further protecting saidexposed areas and providing a stone coating appearance but leaving themetallic facing bare on a portion of the metallic facing covering theinner side of the asphaltic core body adjacent the forward edge andadapted to provide an exterior stone coating appearance to the exteriorcladding, the granular coating leaving the metallic facing bare in thearea adjacent to said outer side bare area of the asphaltic core body,said bare areas of the metallic facing providing improved metal to metaland asphalt to asphalt bonding by an adhesive between adjacent roofinglaminates.
 2. A construction laminate according to claim 1 having anadhesive tab on the inner side for securing laminates to each other inan overlapping fashion.
 3. A construction laminate according to claim 1in which the granular coating has a protective sealant applied over thegranular coating.
 4. A construction laminate according to claim 1 inwhich the asphaltic core body includes a matrix of synthetic plasticmaterial embedded in asphalt for added bulk to increase thickness in thelaminate.
 5. A construction laminate according to claim 1 in which themetallic facing has a thickness of 0.015 to 1.000 mm.
 6. A constructionlaminate according to claim 1 in which the granular coating is selectedfrom materials in the following groups: stone, stone chips, sand,ceramic, quartz, mica, plaster, slag, glass, silica and combinations ofthe foregoing.
 7. A construction laminate according to claim 1 having anadhesive tab on the inner side disposed to lie partially over said baremetallic facing and the asphaltic core body and adapted to bond metal tometal and asphalt to asphalt in adjacent laminates disposed to lie overeach other in overlapping fashion.
 8. A construction laminate accordingto claim 7 in which the adhesive tab is made of asphaltic material.
 9. Aconstruction laminate according to claim 1 wherein the granular coatingapplied to the metallic facing to cover at least a portion of an outersurface thereof is disposed to leave additional selected exposed visibleareas of the underlying metallic facing bare so as to simulate anappearance.
 10. A construction laminate according to claim 1 wherein thegranular coating applied to the metallic facing to cover at least aportion of an outer surface thereof is disposed to leave additionalselected exposed visible areas of the underlying metallic facing bare soas to simulate the appearance of a three tab shingle.
 11. A constructionlaminate according to claim 1 wherein the granular coating applied tothe metallic facing to cover at least a portion of an outer surfacethereof has a granular coating on an exposed outer surface that isvaried in color and distribution.